Structurally reinforced panels

ABSTRACT

A structurally reinforced panel and a method of forming the panel are disclosed. The reinforced panel includes a panel portion, a reinforcement material and a backing material disposed thereon.

FIELD OF THE INVENTION

The present invention relates generally to a structurally reinforcedpanel of an automotive vehicle or other article of manufacture, and moreparticularly to a panel structurally reinforced with a member formed ofa reinforcement material and a backing material.

BACKGROUND OF THE INVENTION

For many years the transportation industry has been concerned withdesigning structural members that do not add significantly to the weightof a vehicle. At the same time, automotive applications requirestructural members capable of providing reinforcement to targetedportions of the vehicle such as vehicle panels. It is known to apply alayer of heat activated matrix material along with a fibrousreinforcement material to panels of automotive vehicles for structurallyreinforcing the panels. However, the fibrous materials that are used toachieve reinforcement of the panels can be expensive. Additionally,desired levels of reinforcement may not be achieved with the presentlyused fibrous materials. Thus, there is a need to replace the presentlyused fibrous material with a lower cost material that can be applied tovehicle panels along with a reinforcement material wherein thereplacement material provides sufficient reinforcement to the panels,the reinforcement material or both.

SUMMARY OF THE INVENTION

The present invention satisfies one or more of these needs by providinga structurally reinforced panel and a method of manufacturing the same.

Accordingly, the present invention provides a structurally reinforcedpanel that includes a reinforcement material, a panel portion and abacking material disposed thereon. The backing material is typically alayer of material that includes at least one rib. In one preferredembodiment, the backing material is a metal layer with a roll formedrib.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and inventive aspects of the present invention will becomemore apparent upon reading the following detailed description, claimsand drawings, of which the following is a brief description:

FIG. 1 is an exploded perspective view of a structurally reinforcedpanel of an automotive vehicle according to an exemplary aspect of thepresent invention.

FIG. 2 is a perspective view of the structurally reinforced panel ofFIG. 1 after formation thereof.

FIG. 3 is a sectional view of the structurally reinforced panel of FIG.2 taken along line 3-3.

FIG. 4 is a sectional view of an alternative structurally reinforcedpanel according to an exemplary aspect of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The invention relates to a structurally reinforced panel of an article,such as an automotive vehicle, a household or industrial appliance,furniture, storage containers or the like, and to a method of formingthe panel. More particularly, the present invention relates to areinforced panel of an automotive vehicle that includes a panel portion,a layer of reinforcement material applied (e.g., attached or otherwisebonded) to at least part of a surface of the panel portion and a layerof backing material positioned (e.g., applied or laminated) upon thereinforcement material, the panel portion or both. Preferably, thereinforcement material of the panel portion is a high strength to weightreinforcement material.

Referring to FIGS. 1 and 2, there is illustrated an exemplary embodimentof a structurally reinforced panel 10. The panel 10 includes areinforcement member 12 applied to a panel portion 14 (e.g., of avehicle door). In the embodiment shown, the reinforcement member 12 iscomposed of a layer 16 of reinforcement material, which is applied to atleast a part of a surface 22 of the panel portion 14, and a layer 24 ofbacking material disposed upon the layer 16 of reinforcement material.

As used herein, the term “panel portion 14” is broadly meant toencompass any component providing a surface 22 suitable for applicationof the layer 12 of composite material thereto. Preferably, the panelportion 14 is metal and includes a surface opposite the surface 22 towhich the layer 12 of composite material is applied. For automotiveapplications, the panel portion 14 may be chosen from a variety ofcomponents of an automotive vehicle. Examples include components of avehicle frame, components of a vehicle body or the like. In one highlypreferred embodiment, the panel portion 14 is at least part of a bodypanel of an automotive vehicle wherein the body panel includes a surfacethat is visible from the outside of the vehicle and wherein that surfaceis opposite the surface 22 to which the reinforcement member 12 isapplied. Examples of such panels include front and rear quarter panels,side panels, hood panels, trunk panels, door panels or the like.

Reinforcement Material

The layer 16 of reinforcement material may be configured in a variety ofshapes, designs, or thicknesses corresponding to the dimensions of theselected panel portion 14 of the vehicle or otherwise configured asdesired. The layer 16 of reinforcement material may be composed of onesubstantially homogeneous material or layer or multiple differentmaterials or layers. Preferably, at least a portion of the reinforcementmaterial is expandable, foamable, curable or a combination thereof.

The reinforcement material is preferably selected so as to beactivatible under a desired condition to soften (e.g, melt), expand,foam or otherwise change states such that the reinforcement material canwet, and preferably bond to adjacent surfaces (e.g., the surfacesprovided by the layer 24 of backing material, the panel portion 14 or acombination thereof). In one embodiment, the reinforcement material isalso selected to cure during or after activation and, upon or aftercure, form a relatively low density, low weight material with highstrength characteristics such as high stiffness for imparting structuralrigidity to a reinforced region of the panel portion 14. In a preferredembodiment, the reinforcement material has a post-cure glass transitiontemperature that is greater than any temperatures to which thereinforcement material may be exposed while in its intended environmentof use (e.g., in an automotive vehicle). Exemplary glass transitiontemperatures may be greater than about 50 degrees Celcius and morepreferably greater than about 70 degrees Celsius. Other desiredcharacteristics of the reinforcement material might include goodadhesion retention and degradation resistance particularly in thepresence of corrosive or high humidity environments.

A number of reinforcement materials may be used to form the layer 16.The reinforcement material may be a thermoplastic, a thermoset or ablend thereof. According to one embodiment, the reinforcement materialis provided as an epoxy-based material, an ethylene-based polymer, or amixture thereof, which when compounded with appropriate ingredients(typically a blowing agent, a curing agent, and perhaps a filler),typically expands, cures or both in a reliable and predictable mannerupon the application of heat or another activation stimulus.

Thus, according to one embodiment, the reinforcement material is aheat-activated, epoxy-based resin having foamable characteristics uponactivation through the use of heat typically encountered in an e-coat orother paint oven operation. Preferably, the epoxy reinforcement materialis such that upon being heated, it structurally bonds to adjacentsurfaces. From a chemical standpoint for a thermally-activated material,such reinforcement material is usually initially processed as athermoplastic material before curing. After curing, the reinforcementmaterial typically becomes a thermoset material that is fixed andincapable of any substantial flowing. Examples of preferred formulationsthat are commercially available include those available from L&LProducts, Inc. of Romeo, Mich., under the designations L-5204, L-5206,L-5207, L-5208, L-5209, L-5214, L-5222 and L-8000.

The layer 16 of reinforcement material may be formed using a variety ofprocessing techniques, machines or the like. Possible processingtechniques for the preferred materials include injection molding, blowmolding, thermoforming, extrusion with a single or twin screw extruderor extrusion with a mini-applicator extruder. In a preferred embodiment,the layer 16 of reinforcement material is extruded using a twin-screwextruder and with the resulting layer 16 having a substantiallycontinuous thickness or a variable thickness. Though preferredreinforcement materials are disclosed other suitable art disclosedreinforcement materials may be used in conjunction with the presentinvention. The choice of the reinforcement material used will bedictated by performance requirements and economics of the specificapplication and requirements. Examples of other possible reinforcementmaterials include, but are not limited to, polyolefin materials,copolymers and terpolymers with at one monomer type an alpha-olefin,phenol/formaldehyde materials, phenoxy material, polyurethane materialswith high glass transition temperatures (including polyureas), andmixtures or composites (optionally including solid or porous metals).See also, U.S. Pat. Nos. 5,766,719; 5,755,486; 5,575,526; 5,932,680(incorporated herein by reference).

Generally speaking, exemplary automotive vehicle applications mayutilize technology and processes such as those disclosed in U.S. Pat.Nos. 4,922,596, 4,978,562, 5,124,186 and 5,884,960, commonly owned U.S.Pat. Nos. 6,467,834, 6,482,486, 6,620,501, 6,634,698, 6,419,305,6,471,285, 6,561,571 and particularly co pending U.S. application Ser.No. 09/459,756 filed Dec. 10, 1999, all of which are expresslyincorporated by reference.

In applications where the reinforcement material is a heat activatedmaterial, such as when a thermally melting, expanding, or foamingmaterial is employed, an important consideration involved with theselection and formulation of the material can be the temperature atwhich the material activates, cures or both. In most applications, it isundesirable for the material to activate at room temperature or theambient temperature in a production or assembly environment. Forautomotive applications, it may be desirable for the reinforcementmaterial to activate at higher processing temperatures, such as thoseencountered in an automobile assembly plant, when the reinforcementmaterial is processed along with the automobile components at elevatedtemperatures. Exemplary temperatures encountered in an automobileassembly body shop oven may be in the range of 148.89° C. to 204.44° C.(300° F. to 400° F.), and paint shop oven temps are commonly about93.33° C. (215° F.) or higher. If needed, for foaming or expanding typereinforcement materials, various blowing agent activators can beincorporated into the composition to cause expansion at differenttemperatures outside the above ranges.

Although many reinforcement materials may be heat activated, otherreinforcement materials that are activated by another stimuli and arecapable of bonding also can be used. Without limitation, suchreinforcement material may be activated by alternative stimuli such as,pressure, chemicals, or by other ambient conditions.

In one desirable embodiment, the reinforcement material is provided as atwo component adhesive or reinforcement material as that term is used inthe art. As a two component material, the reinforcement material wouldtypically be formed by combining an A-side (i.e., a polymeric or resincomponent) with a B-side (i.e., an activating and or curing component).Typically, although not required, the A-side is maintained separate fromthe B-side until shortly before (.e.g, within an hour or more, within 10minutes or within 1 minute) application to the panel portion, thebacking material or both. Examples of A-side materials can includeepoxy-based materials, EVA based materials, polyurethane basedmaterials, combinations thereof or the like. Examples of B-sidematerials can include amines, acid, isocyanates, combinations thereof orthe like.

The two component material is typically designed to cure (e.g.,partially or fully cure) upon addition of the A-side to the B-side. Thematerial may be configured to cure within any amount of time after suchaddition. Typically, however, the material cures within one hour, moretypically within 20 minutes and even more typically within 5 minutes ofaddition of the A-side to the B-side.

The reinforcement material may be provided in a variety of shapes andconfigurations. Thus, the layer of reinforcement material may be square,circular, round, elliptical, geometric, non-geometric, rectangular,combinations thereof or any other shape desired. In the particularembodiment illustrated, the layer 16 of reinforcement material is formedas a strip having a length (L₁) and a width (W₁). For that particularembodiment, the length (L₁) is typically at least twice the width (W₁),more typically at least 5 times the width (W₁) and even more typically10 times the width (W₁). As such, the length (L₁) is typically betweenabout 10 cm or less and about 200 cm or more, more typically betweenabout 30 cm and about 100 cm and even more typically between about 40 cmand about 70 cm. The width (W₁) is typically between about 0.5 cm andabout 15 cm, more typically between about 1.0 cm and about 7 cm andevent more typically between about 2 cm and about 4 cm. The layer 16 ofreinforcement material also has a thickness (T₁) that is typicallybetween about 5 mm or less and about 20 mm or greater, more typicallybetween about 3 mm and about 10 mm and even more typically between about4 mm and about 8 mm.

Backing Material

The backing material may be chosen from a variety of materials. Forexample, and without limitation, the backing material may be formed ofmetal foils, metal sheets, metal screens or the like. As alternativeexamples, the backing material may be formed of polymeric (e.g.,thermoplastic) films, sheets or mesh. In still other alternativeembodiments, the backing material may be formed of cellulose fibermaterial such as impregnated or non-impregnated paper, wood or the like.The backing material may also be formed of filament, fibrous or fabricmaterial, for example, woven or unwoven strands, fibers, filaments orthe like of cotton, fiberglass, nylon, carbon, aramid or othermaterials. It is also contemplated that combinations of each of thesematerials may be employed as the backing material or multiple separatebacking materials may be employed and may be the same or different.

According to a preferred embodiment, the backing material is a metallayer. The metal layer may be partially or substantially entirely formedof metals such as aluminum, steel (e.g., galvanized or galvannealedsteel), iron, titanium, magnesium, zinc, molybdenum, brass, cobalt,nickel, copper, vanadium, chromium, manganese, platinum, gold, silver,combinations thereof or the like combinations thereof or the like.

It is typically preferable for backing material to include at least onerib and potentially a plurality (e.g., 2, 3, 4, 5 or more) of ribs. Suchrib or ribs may be integrally formed with the backing material or may beseparately formed and attached thereto. For example, the rib or ribs maybe integrally molded or extruded as part of the backing material,particularly when the backing material and the rib are formed of metalor polymeric materials. As another example, metal forming techniquessuch as stamping or other techniques may be employed.

In the embodiment of FIGS. 1 and 2, the layer 24 of backing material isa layer of metal with a rib 30 roll formed into the layer. As such, therib 30 is an arched portion of the layer 24 that, as shown, is generallyU-shaped, but may be V-shaped or otherwise shaped as desired. The layer24 typically has a thickness between about 0.5 mm or less and about 10mm or greater, more typically between about 1 mm and about 5 mm andevent more typically between about 2 mm and about 4 mm.

The layer 24 of backing material is also shown as a strip having alength (L₂) and a width (W₂). The length (L₂) and width (W₂) of thelayer 24 typically correspond to (i.e., are within about 2 centimetersof) the length (L₁) and width (W₁) of the layer 24 of reinforcementmaterial, although not required. Such correspondence is seen in themember 12 of FIGS. 1 and 2. Thus, the preferred length (L₂) and width(W₂) of the layer 24 of backing material and a preferred length (L) andwidth (W) of the member 12 and the ratios of length to width aretypically the same as those recited for the length (L₁) and width (W₁)of the layer 16 of reinforcement material. Preferably, although notrequired, the one or more ribs extend substantially the entire length ofthe layer 24 of backing material.

Manufacture

Generally speaking, the member 12 is applied to the panel portion 14 byapplying (e.g., contacting) the layer 16 of reinforcement material to asurface of the panel portion 14 and applying (e.g., contacting) thelayer 24 of backing material to the reinforcement material. This may bedone in any order. According to one preferred protocol, however, thelayer 16 of reinforcement material is applied to the layer 24 of backingmaterial to form the member 12 and then the member 12 is applied to thepanel portion 14. According to another preferred embodiment, the layer16 of reinforcement material is applied to the surface 22 of the panelportion 14 and the layer 24 of backing material is applied to the layer16 of reinforcement material.

In one preferred embodiment, the layer 24 of backing material ispositioned (e.g., laminated) as desired upon a first side of the layer16 of the reinforcement material and a second side of the layer 16 ofreinforcement material is positioned (e.g, laminated) upon the surface22 of the panel portion 14. Preferably, the reinforcement material issufficiently tacky such that the layer 16 of reinforcement material canadhere to the layer 24 of backing material, the surface 22 of the panelportion 14 or both. In that instance, a pressure or force is typicallyapplied to the layer 24 of backing material, the layer 16 ofreinforcement material, the panel portion 14, or a combination thereof,urging the layer 16 of backing material and/or the surface 22 of thepanel portion 14 into intimate contact with the layer 16 ofreinforcement material. In alternative embodiments, particularly whenthe reinforcement material is not tacky, it is contemplated thatmechanical fasteners, additional adhesive or other fastening mechanismsmay be employed to at least temporarily attach the reinforcementmaterial to the backing material the panel portion or both.

Release paper may be applied (e.g., laminated) upon the layer 16 ofreinforcement material preferably while the layer 16 of reinforcementmaterial is still in a tacky potentially pre-activated state.Preferably, a side of the layer 16 of reinforcement material covered bythe release paper remains protected and at least partially tacky suchthat the release paper may be removed and the layer 16 of reinforcementmaterial together with the layer 24 of backing material may be applied(e.g., adhered and/or laminated) to the panel portion 14 as the member12.

The member may be applied generally as desired to the panel portion 14.Preferably, however, the member is applied to panel portions to reducedeformation in selected areas. For targeting certain areas or forproperly fitting the member upon a panel portion, the member may becontoured (e.g. curved or otherwise shaped) to correspond any contoursof the panel portion 14. For example, a door panel or other panel of anautomotive vehicle may be curved (e.g., outwardly curved) and the membermay be correspondingly curved to allow the member to be more easilyattached (e.g., adhered) to the panel.

The layer 16 of reinforcement material may be applied to the panelportion 14, to the backing material or both, in a solid or semi-solidstate. However, the layer 16 may also be applied to the surface 22 ofthe panel portion 14 to the backing material or both in a fluid stateusing commonly known manufacturing techniques. Moreover, thereinforcement material may be heated to a temperature that permits it toflow slightly to aid in wetting the surface 22 of the panel portion 14.Alternatively, the layer 16 may also be applied by heatbonding/thermoforming or by co-extrusion.

For forming the reinforced panel 10 of FIGS. 2 and 3, the reinforcementmaterial may each be activated to flow, expand, foam, cure or acombination thereof. Activation may be induced by a variety of stimulisuch as moisture, chemicals, heat or the like and curing may also beinduced by a variety of stimuli such as time, cooling or the like.

The layer 16 of reinforcement material hardens upon curing such that thelayer 16 can provide added structural integrity to the panel portion 14.Preferably, the layer 16 of reinforcement material adheres, and/orreactively bonds to both the surface 22 of the panel portion 14 and tothe layer 24 of backing material upon curing.

In one embodiment, the layer 16 of reinforcement material, is activatedduring an automotive bake cycle. In such an instance, it is preferablethat the layer 16 of reinforcement material maintains a substantiallyhigh viscosity during the bake cycle such that the layer 16substantially maintains its location between the layer 24 of backingmaterial and the panel portion 14. In another embodiment, particularlywhen a two component material is employed, the layer 24 of reinforcementmaterial cures upon application to the layer 24 of backing material, thesurface 22 of the panel portion 14 or both (e.g., upon addition of theA-side to the B-side).

Additional or Alternative Embodiments

It is contemplated that the, a buffer layer may be applied between thereinforcement member and the panel portion. An example of this isillustrated in FIG. 4. As can be seen, a layer 40 of buffer material isinterposed between the reinforcement member 12 and the panel portion 14.

The layer 40 of buffer material is preferably a material that haselastomeric or compliant properties. The buffer material may include oneor any combination of the following components: one or more polymercomponents (e.g., elastomers, plastomers, rubbers, plastics or thelike), one or more fillers or additives and one or more curing agents oradhesives. Other components may be included in the buffer material aswell such as component for imparting surface tack, magnetism or the liketo the material. Moreover, the buffer material may be water-based,solvent-based, substantially solid or otherwise. Preferably, thecomponents of the buffer material are chosen such that the buffermaterial is capable of viscoelastic recovery during and afterinstallation of the member 12 to the panel portion 14.

Typically the polymer components will include at least one elastomer.Exemplary elastomers include natural and synthetic isoprenes,propylenes, styrene butadiene copolymers, terpolymers of ethylene,isobutene isoprene polymers, butadiene copolymers, nitrile butadienecopolymers, chlorosulphonated polyethylenes, polysiloxanes, polyesters,polyisobutylenes fluorinated hydrocarbon or the like. In one preferredembodiment, the polymer component is at least partially composed of anacrylic elastomer such as an acrylonitrile butadiene terpolymer. Inanother preferred embodiment the polymer component is at least partiallycomposed of a styrene butadiene rubber. In highly preferred embodiments,the elastomer of the buffer material is carboxylated for assisting thebuffer material in adhering to adjacent materials, reacting withadjacent materials or both.

Advantageously, the buffer material is compliant with respect to thereinforcement material during activation, cure or both of thereinforcement material. Such compliance allows the reinforcementmaterial to expand, contract or both while the buffer material absorbsstress that might otherwise be exerted upon the panel portion 14. Inthis manner, the buffer material assists in minimizing any deformationof the panel portion 14 that might otherwise be caused by the expansionor contraction of the reinforcement material. As an additionaladvantage, use of the buffer material disclosed herein only minimallylessens or does not lessen the reinforcement ability of thereinforcement material. For further explanation of the buffer layer 40and methods of applying the layer, reference may be had to U.S. patentapplication Ser. No. 10/098,952, titled “Structurally ReinforcedPanels”, filed Mar. 15, 2002 and incorporated herein by referenced forall purposes. It is further contemplated within the present inventionthat the layer 24 of backing material may include a fiberglass wovenroving, which is disclosed in commonly owned U.S. patent applicationSer. No. 09/939,152, also titled “Structurally Reinforced Panels” andfully incorporated herein by reference for all purposes.

Additionally it is contemplated that multiple members may be applied toa single panel. In such an embodiment, the members would typically bespaced apart upon the panel portion to maximize the ability of themembers to reinforce the panel portion.

Unless stated otherwise, dimensions and geometries of the variousstructures depicted herein are not intended to be restrictive of theinvention, and other dimensions or geometries are possible. Pluralstructural components can be provided by a single integrated structure.Alternatively, a single integrated structure might be divided intoseparate plural components. In addition, while a feature of the presentinvention may have been described in the context of only one of theillustrated embodiments, such feature may be combined with one or moreother features of other embodiments, for any given application. It willalso be appreciated from the above that the fabrication of the uniquestructures herein and the operation thereof also constitute methods inaccordance with the present invention.

The preferred embodiment of the present invention has been disclosed. Aperson of ordinary skill in the art would realize however, that certainmodifications would come within the teachings of this invention.Therefore, the following claims should be studied to determine the truescope and content of the invention.

1. A structurally reinforced member for an automotive vehicle,comprising: (a) a panel portion of the automotive vehicle; (b) areinforcement member having a length, the reinforcement member being alaminate that includes: i) a reinforcement material layered upon thepanel portion; and ii) a backing material formed as layer and having arib, the backing material layered upon a surface of the reinforcementmaterial.
 2. A structurally reinforced member as in claim 1 wherein thereinforcement material is a two-component material that activates tocure upon exposure of a first component to a second component.
 3. Astructurally reinforced member as in claim 1 wherein the reinforcementmaterial is a heat activatable material that activates to foam and cureupon exposure to a temperature experienced in an e-coat or paint curingoven.
 4. A structurally reinforced member as in claim 1 wherein the ribis roll formed to have an arc.
 5. A structurally reinforced member as inclaim 1 wherein the backing material is formed of metal.
 6. Astructurally reinforced member as in claim 5 wherein the backingmaterial is at least partially formed of aluminum or steel.
 7. Astructurally reinforced member as in claim 1 wherein the panel portionis part of a automotive vehicle panel selected from a quarter panel, aside panel, a hood panel, a trunk panel or a door panel.
 8. Astructurally reinforced member as in claim 1 wherein the length isbetween about 30 cm and about 100 cm.
 9. A structurally reinforcedmember as in claim 1 wherein the layer of reinforcement material has athickness between about 3 mm and about 10 mm.
 10. A structurallyreinforced member as in claim 1 wherein the reinforcement material isactivatable to foam and cure, but is also sufficiently tacky to adherethe layer of backing material to the panel portion prior to activation.11. A structurally reinforced member as in claim 1 wherein thereinforcement material and the backing material are substantiallycoextensive along the length of the reinforcement member.
 12. Astructurally reinforced member as in claim 1 wherein the reinforcementmember is contoured to correspond to a surface of the panel portion. 13.A structurally reinforced panel for an automotive vehicle, comprising:(a) a metal panel portion; (b) a reinforcement member having a lengthand a width, the reinforcement member being a laminate that includes: i)a reinforcement material selected from an epoxy-based material, anethylene-based polymer, or a mixture thereof, the reinforcement materialbeing layered upon panel portion; and ii) a backing material formed oflayer of metal having a metal rib extending along the length of thereinforcement member, the backing material layered upon a surface of thereinforcement material wherein the length is at least twice the widthand wherein the panel portion is an exterior panel of the automotivevehicle.
 14. A structurally reinforced member as in claim 13 wherein thereinforcement material is a two-component material that activates tocure upon exposure of a first component to a second component.
 15. Astructurally reinforced member as in claim 13 wherein the reinforcementmaterial is a heat activatable material that activates to foam and cureupon exposure to a temperature experience in an e-coat or paint curingoven.
 16. A structurally reinforced member as in claim 13 wherein therib is roll formed to have an arc and wherein the backing material is atleast partially formed of aluminum or steel and wherein the panelportion is part of a automotive vehicle panel selected from a quarterpanel, a side panel, a hood panel, a trunk panel or a door panel.
 17. Astructurally reinforced member as in claim 13 wherein the length isbetween about 30 cm and about 100 cm and wherein the layer ofreinforcement material has a thickness between about 3 mm and about 10mm and wherein the reinforcement material and the backing material aresubstantially coextensive along the length of the reinforcement member.18. A structurally reinforced member as in claim 13 wherein thereinforcement material is activatable to foam and cure, but is alsosufficiently tacky to adhere the layer of backing material to the panelportion prior to activation.
 19. A structurally reinforced member as inclaim 13 wherein the reinforcement member is contoured to correspond toa surface of the panel portion.
 20. A structurally reinforced panel foran automotive vehicle, comprising: (a) a metal panel portion; (b) areinforcement member having a length and a width, the reinforcementmember being a laminate that includes: i) a reinforcement materialselected from an epoxy-based material, an ethylene-based polymer, or amixture thereof, the reinforcement material being layered upon panelportion; and ii) a backing material formed of layer of metal having aroll formed metal rib extending along the length of the reinforcementmember, the backing material being shaped as an elongate panel that islayered upon a surface of the reinforcement material. wherein the lengthis at least 10 times the width; wherein the panel portion is an exteriorpanel of a door of the automotive vehicle; wherein the reinforcementmaterial is a two component material that activates to cure uponexposure of a first component to a second component, the first componentincluding an epoxy resin and the second component including an amine.21. A structurally reinforced member as in claim 20 wherein the rib isroll formed to have an arc and wherein the backing material is at leastpartially formed of aluminum or steel and wherein the length is betweenabout 30 cm and about 100 cm and the layer of reinforcement material hasa thickness between about 3 mm and about 10 mm and wherein thereinforcement material and the backing material are substantiallycoextensive along the length of the reinforcement member and wherein thereinforcement member is contoured to correspond to a surface of thepanel portion.